Absorbent textile fabric



P 1964 S-ELTZER 3,150,693

ABSORBENT TEXTILE FABRIC Filed Se t. 28, 1961 IRS MENTOR: NORMAN L. SELTZER ATTORNEYS United States Patent 3,150,693 ABSORBENT TEXTILE FABRIC Norman L. Seltzer, Princeton, N.J., assignor to The Kendall Company, Boston, Mass., a corporation of Massachusetts Filed Sept. 28, 1961, Ser. No. 141,449 11 Claims. (Cl. 139-683) This invention relates to woven textile fabrics and particularly those fabrics which are formed to have a high degree of absorbency, resistance to fraying and raveling, and other desirable characteristics which makes the same particularly adaptable for use as diapers.

More particularly, this invention relates to interwoven fabrics wherein a plurality of elongate panels are provided which are constructed and arranged to make the fabric particularly usable as a diaper. This diaper provides a central portion which is adapted to cover the crotch area of the wearer when in use having increased absorbency, ease of cleaning and softness, intermediate portions which are adapted to be overlapped and pinned together when the diaper is in use having increased resistance to fraying by the diaper pins and, due to lesser bulk, increased ease of insertion of the pins, while still providing the requisite softness, and outer portions having antiravel characteristics.

In essence, the fabric of this invention is formed with an elongate center panel section, a pair of adjacent elongate intermediate panel sections, and a pair of adjoining elongate side panel sections, all arranged parallel to each other. The center panel section is formed of a sufiicient dimension to serve as an absorbent panel when the fabric is used as a diaper with the center panel section extending through the crotch area of the baby. This center panel section is formed of a greater number of independent layers of fabric of a more open weave construction than the adjoining intermediate panel sections to enhance the absorbency and softness thereof and to facilitate the cleaning and removal of body waste therefrom. These characteristics are particularly desirable in the body portion of a diaper, and the center panel of the instant fabric forms such a body portion when the fabric is used as a diaper.

The adjoining intermediate panel sections may be termed pinning bar panels when thinking in terms of a diaper and, in view of the desirability of added strength in this area to prevent dislocation of diaper pins and fraying of the yarns by such pins and the desirability of less bulk to facilitate insertion of the pins therethrough, is formed of a plurality of layers of a lesser number and of a closer weave construction than the center panel. The independent layers of both the center panel and the intermediate panels extend uninterruptedly between the terminal ends of the panels. The pair of side panel sections may be termed pinking bar panels since they are normally formed with a pinked edge to provide anti-ravel characteristics at the edges of the fabric and are preferably formed of a single layer of closer weave construction than the other panels to thus resist raveling to aid in prolonging the life of the diaper.

A Wear strip comprising a band of reinforcing yarns extends transversely of all of the panels, and is interwoven with the yarns making up the panels. This strip serves to define a fold line along which the fabric is adapted to be folded to form the same into a diaper ready for use. The reinforcing yarns, however, are only interwoven with the yarns forming the outside faces of the fabric. This positions the reinforcing yarns on the surfaces of the fabric where wear is most likely to occur and, therefore, where they are needed most while obviating any bulkiness at the fold, particularly with respect to the center panel.

Thus, it is an object of this invention to provide a textile fabric having a plurality of juxtapositioned panels, with the panels being formed of varying weave characteristics to impart varying functional characteristics thereto particularly suitable for use as a diaper fabric having the desired absorbency, resistance to fraying and raveling.

A more specific object of this invention is to provide an interwoven fabric having elongate center, intermediate and side panel sections formed of a varying number of independent fabric layers decreasing in number, but increasing in the closeness of the weave construction out wardly from the center panel section, with the independent layers extending uninterruptedly between the terminal ends of the panel sections.

A further object of the invention is to provide a fabric as thusly described wherein the length of the respective panel sections are of such dimension that the fabric may be readily folded once upon itself to obtain the desired dimensions and characteristics of a diaper ready for use to thus avoid the problems of many diapers presently on the market which necessitate folding a considerable number of times.

It is a further object of the invention to provide a fabric of the character described which is reinforced transversely in all of the panels and in the area where the fabric is adapted to be folded upon itself for forming a diaper ready for use and wherein the reinforcement is provided only on the outside faces of the fabric to provide a concentration of the reinforcement where it is needed most.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds, when taken in connection with the accompanying drawings, in which FIGURE 1 is a plan view of the fabric of the present invention with portions of the layers thereof broken away for clarity in viewing the layers therebeneath;

FIGURE 2 is an enlarged sectional view taken substantially along line 2-2 in FIGURE 1;

FIGURE 3 is an enlarged fragmentary sectional view taken substantially along line 33 in FIGURE 1;

FIGURE 4 is an isometric View of the fabric of FIG- URE 1 in folded condition and stitched to form a prefold-type diaper; and

FIGURE 5 shows, in draft form, one repeat of the layers of the central portion and intermediate portions of the fabric shown in FIGURE 1, the warp yarns running vertically and the filling yarns or picks running horizontally, and the Xs indicating where the Warp yarns pass over the filling yarns.

Referring now to the drawings and more particularly to FIGURE 1, there is shown a fabric broadly indicated by the numeral 10. Fabric 10 is formed of interwoven warp and filling yarns, preferably of a cellulosic and water-swellable material, and comprises a pair of outer panels 11, a pair of intermediate panels 12, and a central or inner panel 13. Panels 11, 12 and 13 are preferably elongate in a fillingwise direction and are bounded at their terminal ends by selvages 14 and 15. It will be noted that all of the panels utilize the same warp yarns, which are separated into groups corresponding to the number of layers of fabric of the respective panels.

Outer panels 11 are formed of the warp and filling yarns which are preferably interwoven to form a single layer of fabric with a design of sufiicient interlacings of sufiicient tightness to minimize raveling, but no so tight as to be harsh or unyielding on the body of the wearer which make the same suitable for pinking bar portions. Panels 11 are preferably formed in the manner shown and described in Dangel et al. Patent No. 2,713,359, with the outer edges thereof preferably pinked as is clearly shown in FIGURE 1.

Intermediate panels 12 are formed of the warp and filling yams which are preferably interwoven to form a pair of independent fabric layers 12a and 12b with a design of suflicient interlacings of sufficient tightness to securely hold the diaper pins and to minimize fraying of the yarns by the pins, but of sufficient looseness so that the diaper pins may be easily inserted therethrough and so that the layers are soft and yielding on the body of the wearer. Layers 12a and 12b are connected to each other only at the selvage edges 14 and 15 and along their side edges where the same are connected to the inner side edges of the panels 11 and to opposite side edges of the inner panel 13, in a manner to be presently described. The double-layer construction of panels 12 provides the desired degree of softness while still providing necessary resistance to fraying of the yarns in the area where diaper pins are adapted to be received and also provides increased ease in inserting pins therethrough.

Panel 13 is formed of the warp and filling yarns preferably interwoven in a plain weave design to form three independent layers 13a, 13b and 130 which extend uninterruptedly between the selvage edges 14, 15 and between the inner side edges of panels 12 where the same are connected to each other and to the layers of panels 12. It is noted that the three-layer construction of the center panel 13 provides a more open weave construction in each of the layers 13a, 13b and 130 than in the layers 12a and 12b of intermediate panels 12 to provide greater absorbency, ease of cleaning and faster drying where the same is needed most when the fabric 10 is to be used as a diaper. Also panel 13 is preferably of a width, i.e. warpwise dimension, substantially the same as the combined widths of intermediate panels 12.

A band of reinforcing yarns broadly indicated at is provided in a medial portion of fabric 10 and extends transversely throughout all of the panels 11, 12 and 13. The band of reinforcing yarns 20 is preferably made up of warp yarns which are interwoven to provide reinforcement on the opposite surfaces of the fabric where the need is the greatest.

As shown, the reinforcing yarns are interwoven in the single layer of the outer panels 11 and in each of the layers 12a and 12b of the intermediate panels 12 as is clearly indicated by the broken away portions in FIG- URE 1. The reinforcing yarns, however, are interwoven only in the outer layers 13a and 13c of center panel 13 as is indicated by the broken away portions in FIGURE 1 and more clearly by the sectional showing thereof in FIGURE 3.

Referring now to FIGURE 4, the fabric 10 is shown as being folded once upon itself, which is preferred to present the fabric as a diaper ready for use. It is noted that in such a diaper, center panel 13 forms the body portion and intermediate panels 12 are disposed in the position where diaper pins are normally inserted. It is noted that the fold line is intermediate the side edges of the band of reinforcing yarns 20 so that the same reinforces the folded fabric along the fold line where wear is most likely to .occur. The fabric 10 thus folded may readily be used as a conventional diaper, or it may be formed into a prefold-type diaper by stitching the folded fabric portions together along a line adjacent the connected edges of the panels 11 and 12 as is indicated at 21, 22. Seams 21, 22 are preferably inserted in panels 12 to permit the outer panels or pinking bar portions 11 to lie flat and to obviate curling or turning back of the pinking bar portions upon themselves.

It is noted that, if the outer surface of the prefold-type diaper becomes excessively worn, the stitching 21, 22 may be removed, the fabric folded in the opposite manner and re-stitched to present an unworn outer surface. This feature materially increases the life of prefold-type diapers thereby reducing replacement costs.

Referring now to FIGURE 5, the area of the design within the bracket 13 comprises one repeat of the weave of the center panel 13. The numbers 1, 2, 3, 4, 5 and 6 reading from bottom up along the left-hand side of the design correspond to the order in which the picks or filling yarns are inserted into the fabric and the numbers 1, 2, 3, 4, 5 and 6 along the bottom of the design correspond to the warp yarns which form the shed in which the picks are inserted. It is noted that warp yarns 1 and 4 are used to form one of the layers of the center panel such as layer warp yarns 2 and 5 are used to form another of the layers such as layer 13b; and warp yarns 3 and 6 are used to form the remaining layer such as 130. Further, it is noted that the picks progress from one layer to another in weaving the fabric. Thus, picks 1 and 4 in each repeat are interwoven with the warp yarns 1 and 4 to form layer 13a; filling picks 2 and 5 are interwoven with the warp yarns 2 and 5 to form layer 13b; and picks 3 and 6 are interwoven with the warp yarns 3 and 6 to form layer 130.

The area of the weave design shown in FIGURE '5 which is bounded by bracket 12 corresponds to one repeat of the weave design for the intermediate panels 12. It is noted that warp yarns l, 3 and 5 are used in the weaving of one of the layers of panels 12 such as layer 12a, and the remaining warp yarns 2, 4 and 6 are used in the weaving of the other layer 1212. It is further noted that alternate picks such as 1, 3, 5, 7, 9 and 11 are interwoven with the warp yarns 1, 3 and 5 to form layer 12a and picks 2, 4, 6, 8, 10 and 12 are interwoven with the warp yarns 2, 4 and 6 to form layer 12b.

It will, therefore, be apparent that a novel fabric particularly adapted for use as a diaper is provided having a pair of outer panels with anti-ravel characteristics, a pair of intermediate panels having the desired softness to prevent irritation while having the necessary anti-fraying strength, openness of weave and lack of excessive bulk to serve as pinning bar portions, and a center panel having increased softness, absorbency and ease of cleaning. Further, a novel fabric is provided embodying the aforementioned characteristics which is easier to prepare as a diaper ready for use and one which may be made into a prefold-type diaper with a minimum of folding and stitching.

In the drawing and specification there has been set forth a preferred embodiment of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

That which is claimed is:

1. A textile fabric of interwoven warp and filling yarns comprising a pair of elongate parallel outer panels, a pair of elongate parallel intermediate panels having their outer longitudinal edges connected to the inner longitudinal edges of said outer panels, and an elongate inner panel connected along its opposite longitudinal edges to the inner longitudinal edges of said intermediate panels, said intermediate panels and said inner panel each comprising a plurality of independent layers of woven fabric with the layers in the inner panel being greater in number than those in the intermediate panels.

2. A textile fabric of interwoven warp and filling yarns comprising a pair of elongate parallel outer panels, a pair of elongate parallel intermediate panels having their outer longitudinal edges connected to the inner longitudinal edges of said outer panels, and an elongate inner panel connected along its opposite longitudinal edges to the inner longitudinal edges of said intermediate panels, said intermediate panels and said inner panel each comprising a plurality of independent layers of woven fabric with the layers in the inner panel being greater in number than those in the intermediate panels, each of the layers of said intermediate panels being formed of a greater number of yarns per inch than each of the layers of said inner panel such that the inner panel is of a more open-weave construction.

3. A textile fabric of interwoven warp and filling yarns comprising a pair of elongate parallel outer panels, a pair of elongate parallel intermediate panels having their outer longitudinal edges connected to the inner longitudinal edges of said outer panels, and an elongate inner panel connected along its opposite longitudinal edges to the inner longitudinal edges of said intermediate panels, said panels extending lengthwise in the direction of said filling yarns, said outer panels being formed of a single layer of woven fabric, said intermediate panels and said inner panel each comprising a plurality of independent layers of woven fabric with the layers in the inner panel being greater in number than those in the intermediate panels, each of the layers of said intermediate panels being formed of a greater number of yarns per inch than each of the layers of said inner panel such that the inner panel is of a moreopen-weave construction.

4. A textile fabric of interwoven warp and filling yarns comprising a pair of elongate parallel outer panels, a pair of elongate parallel intermediate panels having their outer longitudinal edges connected to the inner longitudinal edges of said outer panels, and an elongate inner panel connected along its opposite longitudinal edges to the inner longitudinal edges of said intermediate panels, said panels lrunning in the direction of said filling yarns uninterruptedly throughout the fabric, said outer panels being formed of a single layer of woven fabric, said intermediate panels comprising a pair of independent layers of woven fabric, said inner panel comprising three independent layers of woven fabric, the independent layers of said inner and intermediate panels being connected at the selvage edges of the fabric and extending uninterruptedly therebetween, each of the layers of said intermediate panels benig formed of a greater number of yarns per inch than each of the layers of said inner panel such that the inner panel is of a more open-weave construction.

5. A textile fabric of interwoven warp and filling yarns comprising a pair of elongate parallel outer panels, a pair of elongate parallel intermediate panels having their outer longitudinal edges connected to the inner longitudinal edges of said outer panels, an elongate inner panel connected along its opposite longitudinal edges to the inner longitudinal edges of said intermediate panels, said intermediate panels and said inner panel each comprising a plurality of independent layers of woven fabric with the layers in the inner panel being greater in number than those in the intermediate panels, and a band of interwoven reinforcing yarns extending transversely throughout all the panels of the fabric in a medial portion thereof and adapted to define a fold line where the fabric is adapted to be folded upon itself, said reinforcing yarns in said inner panel being interwoven only in the outer layers thereof.

6. A textile fabric of interwoven warp and filling yarns comprising a pair of elongate parallel outer panels, a pair of elongate parallel intermediate panels having their outer longitudinal edges connected to the inner longitudinal edges of said outer panels, an elongate inner panel connected along its opposite longitudinal edges to the inner longitudinal edges of said intermediate panels, said outer panels being formed of a single layer of woven fabric, said intermediate panels and said inner panel each comprising a plurality of independent layers of woven fabric with the layers in the inner panel being greater in number than those in the intermediate panels, each of the layers of said intermediate panels being formed of a greater num ber of yarns per inch than each of the layers of said inner panel such that the inner panel is of a more open-weave construction, and a band of interwoven reinforcing yarns extending transversely throughout all the panels of the fabric in a medial portion thereof and defining a wear strip of a greater number of yarns per inch than the adjacent portions of the panels, said reinforcing yarns defining a fold line where the fabric is adapted to be folded upon itself, said reinforcing yarns in said inner panel being interwoven only in the outer layers thereof.

7. An absorbent diaper formed of warp and filling yarns interwoven to form in juxtaposed relation an elon gate body portion, a pair of elongate pinning bar portions connected along opposite side edges of said body portion and a pair of elongate pinking bar portions connected 'along the outer side edges of said pinning bar portions, said portions extending lengthwise in the direction of the filling yarns, said pinning bar portions and said body portion each comprising layers of fabric greater in number than said pinking bar portions, and said body portion having greater absorbency than said pinking bar and said pinning bar portions.

8. A soft absorbent diaper formed of absorbent warp and filling yarns interwoven to form in juxtaposed relation an elongate body portion, a pair of elongate pinning bar portions connected along opposite side edges of said body portion, and a pair of elongate pinking bar portions connected along the outer side edges of said pinning bar portions, said body and pinning bar portions each comprising a plurality of independent layers of interwoven warp and filling yarns, the layers of said body portion being greater in number and of greater width than the layers of said pinning bar portions, each of the layers of said pinning bar portions having a greater number of yarns per inch than each of the layers of said body portion such that the layers of the body portion are of a more open-weave construction to provide greater absorbency and to facilitate cleaning and the removal of body waste while providing more strength in the area where pins are adapted to be received.

9. A soft absorbent diaper formed of warp and filling yarns of a cellulosic and water-swellable material which are interwoven to form in juxtaposed relation an elongate body portion of three independent layers, a pair of elongate pinning bar portions of two independent layers, the independent layers of said body portion and said pinning bar portions extending uninterruptedly between the terminal ends of said portions, and a pair of elongate pinking bar portions of a single layer, each of the layers of said pinning bar portions having a greater number of yarns per inch than each of the layers of said body portion to provide a more open-weave construction in the body portion to obtain greater absorbency where it is needed most and to facilitate cleaning and the removal of body waste while providing greater anti-fraying strength in the area where pins are adapted to be received, and the single layer of said pinking bar portions having a greater number of yarns per inch than each of the layers of said pinning bar portions to provide the desired antiravel characteristics.

10. An absorbent diaper formed of warp and filling yarns interwoven to form in juxtaposed relation an elongate body portion, a pair of elongate pinning bar portions connected along opposite side edges of said body portion and a pair of elongate pinking bar portions connected along the outer side edges of said pinning bar portions, said pinning bar portions and said body portion each comprising layers of fabric greater in number than References Cited in the file of this patent said pinking bar portions, body portion having UNITED STATES PATENTS greater absorbency than said pinklng bar and said pmmng bar portions, and a band of reinforcing yarns extending 776,087 Robltscl'lek 1904 transversely throughout the diaper in a medial portion 5 2150261 Golfilsmlth July 22, 1941 thereof and defining a fold line where the diaper is 2,845,069 Jarmson er a1 y 29, 1958 adapted to a folded 2,991,786 Sullivan July 11, 196].

11. The structure set forth in claim 10 wherein the ,995,154 Seltzer Aug. 8, 1961 diaper is folded along the band of reinforcing yarns and 3,030,956 Nichols Apr. 24, 1962 the folded-over portions are secured together by stitching 10 3,072,124 Jamison J an. 8, 1963 to form a prc-folded diaper. 

1. A TEXTILE FABRIC OF INTERWOVEN WARP AND FILLING YARNS COMPRISING A PAIR OF ELONGATE PARALLEL OUTER PANELS, A PAIR OF ELONGATE PARALLEL INTERMEDIATE PANELS HAVING THEIR OUTER LONGITUDINAL EDGES CONNECTED TO THE INNER LONGITUDINAL EDGES OF SAID OUTER PANELS, AND AN ELONGATE INNER PANEL CONNECTED ALONG ITS OPPOSITE LONGITUDINAL EDGES TO THE INNER LONGITUDINAL EDGES OF SAID INTERMEDIATE PANELS, SAID INTERMEDIATE PANELS AND SAID INNER PANEL EACH COMPRISING A PLURALITY OF INDEPENDENT LAYERS OF WOVEN FABRIC WITH THE LAYERS IN THE INNER PANEL BEING GREATER IN NUMBER THAN THOSE IN THE INTERMEDIATE PANELS. 